PM932 CNC Build

[jbolt]

More progress. Getting close to completion. Finished all the electrical wiring and managed not to let any of the magic blue smoke escape.

Got the home/limit switches installed. I originally planed on using optical switches in sealed enclosures but decided to install inductive proximity switches simply because the install was simpler. These may be temporary or permanent depending on performance. The z and x switch are out of the way or protected from coolant and chips but I still need to make a cover and wiper for the y switch.

Coolant system (pond pump in a bucket) is hooked up and running via a switch on the control panel. For now the coolant pump will be switched manually but I have provisions to run it from Mach3 if I decide to do so in the future.

The lights on the machine are Malibu 20w halogen garden lights run by a 12vac power supply in the control box. Lights are on magnetic bases so they can be moved around for better positioning depending on the work piece. I have used the same lights on my Smithy Granite for the last 10 years with great success.

Started on the coolant enclosure today. The framework is installed, just need to finish hanging the rest of the shower curtain liners.

Next step is o make the protective covers for the x and y motors and belts.

All three axis have been powered up and jogged back and forth. It's really satisfying to finally see things moving.

Jay

 

[Boswell]

Very Impressive Jbolt. Thanks for all the pictures. I really like the chip pan.

 

[bvd1940]

I believe tools are meant to be used. I can't wait to get it messed up with coolant and chips!

Got your ball screws yet?

No, found out there on a slow boat from China lol.:nuts:
Oh well that gives me some time to get a few things ready.

 

[jbolt]

Woo Hoo! It"s ALIVE!

Ran my first test part today. I don't have the motor splash guards made yet so I ran some plastic sheet. Made the drawing in Solidworks and saved it as a dxf file. Imported the dxf into d2nc for the g-code. The circles came out spot on but the outside is 0.002" under size. Not sure if this is due to running the plastic dry, backlash or the motors need more tuning.

Jay

 

[jbolt]

Spent some time today making mock ups of the lower motor cover. I could have just done it in CAD but sometimes I find it easier to do physical mock ups to see how parts interact in real tine. Once I had the mock up done to my satisfaction I then did them in CAD. Solidworks has a sheet metal tool set which allows you to flatten the part and make a template. All the parts are cut out ready to bend this weekend when I can get into the robotics lab to use the brake.

 

[fatphatboy88]

Looks great Jbolt. Also about the plastic you cut being under size. Have you measured your end mills to see exactly what their true size is and are you running any cutter compensation? I ran into that problem at work where outside profiles were coming out +.003" and inside pockets were -.003". Turned out my 1/2" cutter was .006" under sized at .494". If that isn't it then you can always run machine compensation to make up the difference.

 

[jbolt]

Finished the motor covers and got them installed. Decided to make a vise speed handle as a first project. The plastic part is a test part I ran prior to having splash guards on. The g-code for plastic part was done in D2NC. The aluminum parts g-code was generated from HSM Express which is a free 2.5D CAM software that is used from within Solidworks. HSM is a lot more difficult to use out of the box but I like the fact that integrates with Solidowks. I'm having trouble with the post processing code not matching what I see in the CAM simulations. So far I have done the drilling ops, the hex holes and a fixture to hold the parts to do the outer contour. I also plan on doing a chamfer on the edges. Video is the end of the final profiling pass on the fixture.

[video=youtube;D5uw1u6N960]https://www.youtube.com/watch?v=D5uw1u6N960[/video]

 

[jbolt]

Finished up the vise handle. Tried using hsm express but kept running into post processing problems with Mach3 so I finished with D2NC.

 

[JimDawson]

Nice job. Congratulations on your first successful run.

 

[jbolt]

Thanks Jim. Thanks for your help on the wiring.